Electrolytic condenser



June 15, 1943.

K. G. COMPTON ELECTROLYTIC CONDENSER Filed Marsh 25, 1941 llllllllll [I III/IIIIIIIIIIIIIIIIIIIIIIIIIIIIIII m w RT. R 0 m MW v m w Patentea June 15, 1943 hlliEtllsYTlC CQNDENSER Kenneth G. Compton, Madison, N. 3., asslgnor to ill elephone Laboratories, Incorporated,

New orh, N. Y a corporation of New York Annllcation March 2%. Nil, Serial No. 385,053

it claims. (or. ire-sit) condenser is inversely proportional to the thichness of the dielectric between the armatures. and the dielectric in an electrolytic condenser is extremely thin, it is possihle with electrolytic condensers to obtain capacities many times greater than those of other types oi condenser-s having the same armature area but dii ierent dielectric, and thus to obtain very large capacities in a small space.

The electrolytic condensers may be broadly classified as the wet" type and the "dry type. in the "wet 'tyne, a pair of spaced metallic armatures, at least one having thereon a dielectric usually an oxide flhn, is suspended in a suitable electrolyte which is a liquid of conslderahle mobility at room and the ordinary range oi operating temperatures. The electrolyte and at least one armature are disposed in a sealed container to prevent leakage, said con tainer being, if desired, one of thearmatures.

in the "dry type of electrolytic condenser. l

the electrolyte is of such nature or so carried that it does not now readily if at all at room or operating temperatures and thus avoids one of the :unary disadvantages of the wet" type of or menses-that of leakage. The .dry" type of condenser, therefore, can be mounted in any position, whereas the range of cositions in which the wet type can be mounted is usually limited Toy the necesmty of avoiding leakage. 'lo promote these advantages it is preferable in the "dry" type of condenser that the electrolyte itself be of such a nature that it does not flow appreciably ii at all at room or the ordinary range of temperatures.

In the dry' time oi condenser, furthermore, the armatures are usually separated by a porous spacer, usually of textile or fabric, impregnated with the electrolyte. Usually such a condenser comprises two porous spacers and two metal foil ormatures in interweaved relation, the whole being rolled into a cylinder or the like and inserted into a suitable lid-tight case, the spacers being impregnated with the electrolyte.

ductlvity of the electrolyte.

The present invention relates more particu- Early to dry" type electrolytic condensers.

The electrolyte in such a condenser comprises an ionized substance which provides the con- In general, it is desirable that the conductivity of the electrolyte be as high as possible in order that the internal resistance of the condenser he low. Solid crystalline electrolytes have been proposed for use in dry type condensers but are, in general, characterized by the disadvantage that, due too. laclr of ionic mobility, their conductivity is low. Therefore, amorphous electrolytes are generally employed. To minimize the possibilities of leakage; to minimize the escape of the liquid electrolyte from between the armatures particularly it it is impreenated in a spacer between the armatures; to prevent settling of the liquid electrolyte, particularly ii it ,is impregnated in a spacer; and to inhibit in the condenser move-'- znent of the liquid with respect to the armatures since such movement tends to deteriorate the delicate him on the armature, it is advantaueous that the viscosity of the liquid electrolyte he so high that it does not tend to flow appreciably at room or operating temperatures.

The employment of a liquid electrolyte oi such high viscosity, however, causes dimculties in the introduction of the electrolyte between the armatures. For example, it is dimcult to obtain thorough impregnation oi the porous Spacers if the electrolyte is of high viscosity. Vv'lth an electrolyte of hieh viscosity it is also extremely diihcult to obtain thorough impregnation of the armatures when they are of a porous nature or have their surfaces etched to increase their eilective surfaces and hence the capacity of the the viscosity of the electrolyte is not sumciently ployed and even though impregnation is done after assembly of the mechanical parts of the condenser. This is accomplished by employing an electrolytic liquid which is of high viscosity at room or operating temperatures and which has incorporated therein a minor proportion of a substance which greatly reduces' the viscosity of the electrolyte at elevated temperatures at which the electrolyte is impregnated but which does not reduce the viscosity or even increase the viscosity of the electrolyte at room or ordinary operating temperatures.

The present invention will be discussed in connection with the accompanying drawing in which:

Fig. 1 is a sectional elevation oi one form of condenser embodying the present invention;

Fig. 2 is a perspective of the wound foil armatures and spacers oi said condenser; and

Fig. 3 is an elevation to an enlarged scale of a portion of the illustrated condenser showing the armatures and spacers.

According to the present invention an amorphous electrolyte suitable for the dry" type of condenser, having a viscosity sufliciently high at room or ordinary operating temperatures to prevent a tendency to iiow appreciably, if at all, but permitting suiiicient ionic mobility of one or more ionized substances contained therein to have good conductivity, may include as a predominant constituent other than water one or more suitable water-soluble reaction products oi a suitable polyhydric alcohol such as ethylene glycol, diethylene glycol, triethylene glycol, or one oi the hexahydric alcohols, mannitol, sorbitol or dulcito], with a suitable weak polybasic acid, such as boric acid, tartaric acid, "citric acid or fumaric acid.

Such reaction products are prepared by heating the alcohol and the weak polybasic acid until reaction occurs. In some cases, pohrmerization may occur. The interaction should not be carried out until a solid is formed, but should be continued until a 'thick liquid oi high viscosity at room temperature is attained. Such reaction product is. advantageously mixed with a small quantity of an ionizable substance, such as one or more weak acids and/or salts oi weak acids .with water as a solvent, to increase the conductivity. Highly disassociated ions such as chloride, sulphate or nitrate ions should be avoided in condensers having an oxide dielectric illm formed on one or more 01' the metal armatures since they are extremely detrimental to such him. For example, such highly disassociated ions are detrimental to oxide films iormed on armatures of aluminum .or magnesium which are usually employed.

Electrolytes or electrolytic condensers containing such reaction products may have their hydrogen ion content readily ldlusted to a pH value in the vicinity oi neutrality for the purpose oi protecting the dielectric oxide films on the armatures. The oxide iilm on a condenser armature is ordinarily soluble in both acid and alkaline solutions, whereiore it is desirable that the pit value oi the electrolytebewithintherange oi 5- to 8.5 in order to be within the range of maximum insolubility oi the dim and thus increase the liie oi the condenser. 11' the reaction product in water solution a crlginallfacidic, as a usual]! -thecase'Jtspflveluemayberaisedlirytheadditionoiasmallamountoiasuitable alkali. such may be added to advantage as a butler mixture. The alkali, weak acid and salt of weak acid ionized in water in the electrolyte advantageously increase the conductivity oi the electrolyte.

The viscosity oi the electrolyte is governed to a certain extent by the initial viscosity oi the reaction product and by the amount of water present in the electrolyte. To have the electrolyte oi suillcient viscosity at room or ordinary operating temperatures to have the desired noniiowing properties, that is, of a viscosity on the order oi 100 centipoises or more at 25 C. it should contain no more than about 35 per cent oi water, and may contain as low as 5 per cent. Lower proportions oi water in general provide higher viscosities. With viscosities on the order of or greater than that indicated, such an electrolyte can be impregnated only with diiiiculty even though its temperature is elevated to the neighborhood oi 100 C. or more tor the purposes oi impregnation.

According to the invention, however, the electrolyte includes from 5 per cent to 30 per cent oi one or more substances each oi which is solid at room and ordinary operating temperatures, which has a melting point lying between about C.

and C., which is solublein water, and which is compatible with but not reactive with the reaction product oi the weak polybasic acid and polyhydric alcohol iorming the larger constituent of the electrolyte. Amides of from two to six carbon atoms possessing the above-indicated characteristics of melting points, solubility in water and low viscosity above the melting point, such as acetamide, lactamide and propionamide, are examples of substances which may be so employed. An electrolytic liquid of the above type having incorporated therein one or more of such substances has a viscosity at impregnation temperatures in the neighborhood oi 100 0. very greatly less than that of an electrolyte in which such substance is not present. Indeed, at such temperatures its viscosity approaches that oi light oil or kerosene, and may even be on the order of the viscosity of water. Consequently, electrolytic condensers can be very readily impregnated with such an electrolyte even aiter mechanical assembly. The electrolytic liquid embodying one or more oi such substances, moreover, does not have its viscosity at room or ordinary operating temperatures decreased, but may have it increased, wherei'ore the above-indicated seemingly contradictory advantages oi ease oi impregnation and high viscosity at room or ordinary operating temperatures are provided.

In the condenser shown in the drawing, which illustrates one embodiment oi the invention, each oi the two armatures I and 2, constituting the plates of the condenser. comprises a sheet oi aluminum foil oi high purity. The ioil I constituting one oi the armature; has a dielectric iilm I oi aluminum oxide iormed on its suriaces. The two sheets oi ioii I and 2 are wound into a cylindrlcal coil 4 with sheets I oi porous paper or the like therebetween acting as spacers to keep the toil separated and as a means for holding the electrolytic liquid which is impregnated in said spacers between the ioih'l and 2. Lead 0 is isstened in electrical contact with one 0! the ioils and lead I is similarly connected to the other to". both leads being disposed-at tion oi coil I. Inch 0! trolyte. as by a coating of suitable insulating material.

The coil 4 is contained in an aluminum can I.

In the illustrated embodiment the leads 6 and I protrude through the integral end wall 8 of can t, being insulated from each other and from the can by suitable rubber washers l0. Plastic sealing material Ill, such as a suitable asphalt; is disposed in this end of the condenser between the end of coil .t and the end 8 of can 8. The other end wallxl 2 of the can, is formed by the edge of the can which has been spun or bent over and coated with suitable plastic sealing material.

The spacers b are saturated or impregnated with the electrolyte l3 which also fills the space between the coil d and the can below the top of the coil. The electrolyte is a stiff liquid of the hind described above embodying the invention, and has a viscosity of at least 105i} centipoises at 25 C. and flows very little, if at all, at room or "ordinary operating temperatures.

Exceptional advantages are provided accord-- ing to the present invention when the electrolyte comprises as a major constituent a reaction prodnot of a hexahydric alcohol, such as mannitol, with a weal: polybasic acid, such as boric acid together with a substance, such as aoetamide, which greatly decreases the viscosity of the electrolyte at temperatures on the order of lull (3. without decreasing its viscosity at low temperatures. By employing such a reaction product in an electrolyte it is possible to obtain an electrolyte containing water in which conducting substances can be ionized and having both exceptionally high viscosity at room or ordinary operating temperatures and exceptionally good conductivity, qualitie hitherto considered incompatible and practically impossible toobtain aimultaneously. Apparently the large number oi hydroxyl groups of the alcohol on esteriflcation cause polymerization or the formation oi large complex molecules which in aqueous solution under proper conditions lend themselves to the formation of a gel which, however, permits good ionic mobility for conducting ions.

It is advantageous lac-employ inannitol as the henahydric alcohol and boric acid as the weak polybasic acid to form the reaction product for the electrolyte, and the following discussion will describe the production of an electrolyte enihodying a reaction product formed off these substances and providing euceptionally good results. To form the electrolyte, mannitol of high purity and having a low content of active ions such as chloride or sulphate ions is melted and boric acid or borio anhydride is added. The minture is heated until it boils and held there until a constant boiling point is reached. The attainment of a constant boiling point indicates substantially complete esteriflcation oi the manni- 5, the precipitation does not occur. As the pa is progressively raised, the mannitol borate becomes more viscous until at a. pH value of about 8,-the aqueous solution 01 mannitol borate becomes a. still! gel due to peptization.

To minimize the harmful eflect of the alkalinity in shortening the life of the condenser and increasing its leakage current, suflicient boric acid, or, preferably, boric acid and sodium borate, is added in the form 01 a. solution to reduce the pill to a value between about and about 8.5, preferably about 7. This addition of a bufier mixture aids the conductivity and tends to stabilize the pH, but does not appreciably reduce the viscosity of the mannitol borate. The final pH oi the electrolyte must be determined after dilution until its water content is in the neighborhood ct 5d per cent because the high viscosity of the electrolyte interferes with the pH measurement.

The water is then evaporated from the electrolyte to bring the water content down to between 5 per cent and 35 per cent. With the water content in this range, the electrolyte at room temmrature is a very stiff, tough, jelly-hire substance. lts final viscosity is at least about lilil centipoises at 25 0., the viscosity being determined to a certain eutent by the amount of water present, While the electrolyte constitutes a solution of mannitol borate in water, it appears that due to the molecular size oi the mannitol borate the solution has colloidal properties.

From about 5 per cent to about at per cent oi acetamide is added to and thoroughly mixed with the electrolyte while it is maintained at a temperature of about 100 C. The amount of acetamicle which is added varies with the water content of the electrolyte for best results. In an electrolyte having a water content of about 30 per cenhwhich is advantageous for most uses, from 15 to 2d per cent of acetamide provides exceptionally good results. When incorporated v in an electrolyte to be used in connection with a condenser having aluminum armatures, the acetanilde should be free of active ions such as sulphate, chloride or nitrate ions which will tend to corrode the aluminum.

in making the illustrated condenser, aluminum foil sheets are employed having a purity in the neighborhood of 99.993 per cent and a thickness from .lilll to .llll3 inch. The fell on which it is desired to form a dielectric film is continuously passed through a forming apparatus oi the tel with the boric acid. "The viscosity of the trolyte being advantageously determined by.

either the colorimetric or glass electrode method. my the addition of a suitable alkali such as-sodium hydroxide, the pH of the solution is raised to about 8.5 or more. At a pH value below about 5, the mannitol borate will precipitate as the hot a ueous solution cools; at pH values above about conventional type at the required voltage, being immersed in a. formiut, electrolyte composed of a mixture of boric acid and borer: in a solution the pill of which is approximately 6.5. For condensers operatinu on voltages up to lllll the concentration is slightly less than that required for saturation. The forming operation is carried on at room temperature without stirring and with the toil strip passing through the bath at the rate oi approximately one foot 2. minute. The toll is then washed with distilled water and dried. Ii desired, the foil may be subjected before the forming operation to an initial cleaning bath of chromic acid, after which it may be wa hed with distilled water before being passed to the forming bath.

it. iormed foil, an uniormed foil and two spacers are placed in interleaved relation, with one or the spacers between the two foils. Each oi the spacers is formed oi at least one sheet of mate rial which is preferably a sheet of absorbent tissue paper which has been treated with viscose, a sodium salt at cellulose nanthate, to improve its resistance to disintegration. It should be free oi deleterious ions such as chloride or sulphate ions. The leads 6 and I are connected to their respective foils and insulated and the foils and spacers are then wound into a compact cylindrical roll, as is shown in Fig. 2 of the drawing, in such manner that the roll is made up oi alternate foils and spacers. Several turns oi the above-described paper may also be wound about the outside of the coil and cemented. The coil is then assembled as is described above in an aluminum can, the bottom of which is left open [or impregnation purposes.

impregnation is accomplished with the electrolytic liquid heated to about 100 C., the liquid being introduced into the bottom of the can to obtain ready, thorough impregnation. If desired, the condenser may be impregnated under lytic liquid becomes very still! and jelly-like in nature and has little or no tendency to flow at room or ordinary operating temperatures. The acetamide not only does not render the electrolyte more liquid at room or ordinary operating temperatures but actually appears to increase its viscosity at such low temperatures.

-It is apparent that various modifications may be made in the above-described illustrative condenser and that condensers embodying the invention other than that illustrated may be produced. For example, instead of mannitol, the other hexahydric alcohols such as sorbitol and dulcitol may be employed. Suitable reaction products of other polyhydric alcohols and other weak polybasic acids may also be employed, provided their employment makes possible the production of an electrolyte having high viscosity at operating temperatures with satisfactory conductivity. In some cases, where armatures oi metals other than aluminum are employed, as when tantalum armatures are used, it is not so important to avoid the active ions such .as chloride and sulphate ions. The present invention may also be applied in electrolytic condensers in which no spacers are employed.

It is intended that the patent shall cover by suitable expression in the appended claims whatever ieatures of patentable novelty reside in the invention.

What is claimed is:

1 An electrolyte for electrolytic condensers having a liquid portion of a viscosity of at least about 100 centipoises at 25 C. and comprising. essentially mannitoi borate, from about 5 per cent to about per cent of water, and from 5 prising water and a reaction product of a polyhydric alcohol and a weakpolybasic acid which mass at room or operating temperatures of the condenser has such a high viscosity as to have little or no tendency to flow and which at elevated temperatures has a viscosity suiflciently high to 'render impregnation diillcult, and, in

addition to said mass, at least one water soluble amide 01' from 2 to 6 carbon atoms having amelting point between about C. and about 100 C. which greatly reduces the viscosity of said mass at temperatures at which impregnation of said electrolyte is performed but which does not substantially reduce the viscosity 01' said mass at room or operating temperatures of the condenser.

4. An electrolyte of the character described in claim 3 in which said amide is acetamide.

5. An electrolytic condenser comprising a pair of armatures having therebetween an electrolyte having a viscosity of at least about 100 centipoises at 25 C. and consisting of a mass comprising water and a reaction product of mannitol and a weak polybasic acid which mass at room or operating temperatures oi the condenser has such a high viscosity as to have little or no tendency to flow and which at elevated temperatures has a viscosity suiliciently high to render impregnation diilicult, and, in addition to said mass, at least one water soluble amide of from 2 to 6 carbon atoms having a melting point between about 60 C. and about 100 C. which greatly reduces the viscosity ofl said mass at temperatures at which impregnation of said electrolyte is performed but which does not substantially reduce the viscosity of said mass at room or operating temperatures of the condenser.

6. An electrolytic condenser comprising a pair of armatures having therebetween an electrolyte having a viscosity of at least about 100 centipoises at 25 C. and consisting of a mass comprising water and a reaction product of a hexahydric alcohol and a weak polybasic acid which mass at room or operating temperatures of the condenser has such a high viscosity as to have little or no tendency to flow and which at elevated temperatures has a viscosity suiiiciently high to render impregnation dimcult, and, in addition to said mass, at least one water soluble amide oi from 2 to 6 carbon atoms having a melting point between about 60 c. and about 100 c. which greatly reduces the viscosity oi said mass at temperatures at which impregnation of said electrolyte is performed but which does not substantially reduce the viscosity of said mass at room or operating temperatures of the condenser.

7. An electrolytic condenser oi the character described in claim 6 in which said amide in said electrolyte is acetamide.

I. An electrolyte for electrolytic condensers having a viscosity of at least about 100 centiper cent to about 30 per cent of acetamide. said electrolyte having a pH from about 15 to about .5 measured when its water content is about 50 per cent.

2. An electrolyte i'or electrolytic. condensers having a liquid portion of a viscosity of at least about 100 centipoises at about-25' C. and co prising essentially mannitoi borate. from 15 c'mttoilipercentciacetanidaandabout It poises at'about 25 C. and consisting of a mass comprising water and mannitol borate which mass at room or operating temperatures of the condenserhassuchahighviscosityastohave little or no tendency to flow and which at elevated temperatures has a viscosity suflcientiy high to render impregnation oi the condenser diihcult.and.inadditiontosaidmasa,atleast one water soluble amide o! from 2 to 0 carbon a aaiee'i atoms having a melting point between about to" C. and about 100 C. which greatly reduces the viscosity of said mass at temperatures at which impregnation oi said electrolyte is performed but which does not substantially reduce the viscosity oi said mass at rmm or operating temperatures of the condenser.

9. An electrolyte of the character described in claim 8 in whichsaid amide is acetamide.

iii. The method of making an electrolyte for electrolytic condensers comprising incorporating in a mass comprising water and a reaction prodnet of a hezahydric alcohol and a weak polybas'ic acid which mass in the absence of the hereinafter-named component at room or operating temperatures has such a high viscosity as to have little or no tendency to how and at elevated temperatures has a viscosity sumciently high to render impregnation dimcult, at least one water soluble amide of from 2 to 6 carbon atoms having a melting point between about 60 C. and about we 0. which tlyreduces the viscosity oi said mass at elevated imprting temperatures but which does not substantially reduce the viscosity oi said mass at room or operating tome peratures.

ii. The method of mg an electro for electrolytic condensers comprising incorporating in a mass comprising water and a reaction product of a polyhydric alcohol and a weak polybasic acid which mass in the absence of the hereinafter-named component at room or operating temperatures has such a high viscosity as to have little or no tendency to how and at elevated temperatures has a viscosity suficientlyhigh to render impregnation dificult, at least one water soluble amide of from 2 to 6 carbon atoms having a melting point between about 6il C, and about 100 C. which greatly reduces the viscosity of said mass at temperatures at which impregnation of said electrolyte is performed but which does not substantially reduce the viscosity of said mass at room or operating temmratures.

12. The process of claim it in which said amide is acetamide. 

